Edition: January 2013

Specification: Part 204 Installation of Stormwater Drainage

PART 204
INSTALLATION OF STORMWATER DRAINAGE
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

General
Supply of Concrete Pipes and Box Culverts
Excavation
Installation of Pipes and Box Culverts
Backfill of Trenches and Reinstatement of Existing Pavements
Excavation at Inlets and Outlets
Cast-In-Place and Precast Concrete Drainage Structures
Minor Accesses and Junctions
Subsoil Drainage
Property Drainage Connections
Sedimentation
Test Procedures
Hold Points
Measurement
Verification Requirements and Records

Appendix A:
1.

Culvert Installation in Fill

GENERAL

This Part specifies the requirements for the installation of stormwater drainage infrastructure, including concrete
pipes, box culverts, concrete drainage structures, subsoil drainage and miscellaneous stormwater drainage works.
It also includes the installation of pipes and box culverts installed for purposes other than drainage. The works
shall be carried out in accordance with the requirements specified in the Contract Specific Requirements or on
the drawings.
"Unsuitable Material" has the meaning defined in Part 210 "Construction of Earthworks".
Concrete, reinforcing and formwork used in drainage works shall comply with Division 3 "Concrete". Drainage
work under new pavement shall be completed prior to the construction of new pavement.
Documents referenced in this Part are listed below:
AS 1289
AS 1428.4.1
AS 1554.1

Methods of Testing Soils for Engineering Purposes

Design for access and mobility Part 4.1: Means to assist the orientation of people with vision
impairment -Tactile ground surface indicators
Welding of Steel Structures

AS 1597.1

Precast reinforced concrete box culverts - Small Culverts (not exceeding 1200 mm span and
1200 mm height)

AS 1646
AS 2758.1

Rubber Joint Rings for Water Supply, Sewerage and Drainage Purposes
Concrete Aggregates

AS 3610
AS 3996

Formwork for Concrete

Metal Access Covers, Road Grates and Frames

AS 4058
AS 4139

Precast Concrete Pipes

Fibre Reinforced Concrete Pipes and Fittings

AS 4198
AS 4671

Precast Concrete Access Chambers for Sewerage Applications

Steel Reinforcing Materials

AS 4680
AS 9001

Hot-dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles

Quality management systems - Requirements

The work shall be undertaken in accordance with the following drawings:

Drawing

Amendment No.

Drawing No. S-4002, Headwalls:

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sheet 17
sheet 18
sheet 19
sheet 20
sheet 21
sheet 22
sheet 23
sheet 24

Specification: Part 204 Installation of Stormwater Drainage

Driveable, Type 1 RC Pipe and Box Culverts up to 600 mm high

Driveable, Type 2 RC Pipe and Box Culverts up to 600 mm high
for Box Culverts skew angle 0 - 20
for Box Culverts skew angle 21 - 45
for Pipe Culverts 450 - 900 mm diameter, skew angle 0 20
for Pipe Culverts 1050 - 1800 mm diameter, skew angle 0 - 20
for Pipe Culverts 450 - 900 mm diameter, skew angle 21 - 45
for Pipe Culverts 1050 - 1800 mm diameter, skew angle 21 - 45

Drawing No. S-4080, Junction Boxes and Gullies:

sheet 1
Single Pipe Junction Boxes, Types A, B, C
sheet 2
Side Entry Gullies
sheet 3
Combined Junction Boxes and Side Entry Gullies
Sheet 6
Grated Field Pit
Sheet 7
Grated Inlet Pit for Concrete Side Drain
Sheet 13
Special Combined Junction Boxes with Side Entry Gullies or Grated
Inlet.
Drawing No. S-4065:
sheet 1
Concrete Channels and Grate

0
0
0
0
0
0
0
0
5
9
9
1
0
0
6

DPTI standard drawings are available from the following web site: http://www.dpti.sa.gov.au/standards.
2.

SUPPLY OF CONCRETE PIPES, BOX CULVERTS AND PRECAST DRAINAGE STRUCTURES

Concrete pipes, box culverts and precast drainage structures shall comply with Part 203 Supply of Pipes, Box
Culverts and Drainage Structures.
3.

EXCAVATION

3.1

General

Excavation shall comply with Part 207 Trench Excavation and Backfill. Any clearing and grubbing in the line
of the drain, including cutting back of any tree branches, shall conform to the requirements of Part 150
"Environmental Management Requirements" and Part 155 "Environmental Protection Issues".
Over-excavation, taken below the levels specified, shall be filled with the specified bedding material placed in
accordance with Clause 4.4 "Bedding" except that for large box culverts, over-excavation shall be filled with
Grade 10 concrete.
3.2

Support of Utility Services in Excavations

Where Utility Services are encountered in an excavation, the Contractor shall liaise with the appropriate Service
Authority to obtain any requirements for support of the Utility Services and comply with those requirements.
3.3

Removal of Existing Culverts and Drainage Structures

Where specified, the Contractor shall remove any existing pipes, culverts and drainage structures and backfill the
resultant voids in accordance with Clause 5 "Backfill and Reinstatement of Existing Pavements". Any existing
pipes / box culverts that require sealing shall be filled with Grade 10 concrete for a length of approximately 1 m.
3.4

Excavated Material

Material excavated for drainage construction shall be treated in accordance with the requirements of Part 210
"Construction of Earthworks".
3.5

Inspection after Excavation

Following completion of excavation, a HOLD POINT shall apply.

If foundation preparation concrete is not to be used, the Contractor shall undertake proof rolling to verify the
strength of the subgrade and identify any unsuitable material. For pipes, small box culverts and drainage
structures, 2 passes of a vibrating plate compactor (Wacker Model BPU 3345 or similar) shall be used. For large

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Specification: Part 204 Installation of Stormwater Drainage

box culverts, a roller with a minimum weight of 1 tonne shall be used. Where foundation preparation concrete is
to be placed proof rolling will not be required.
The Contractor shall remove and replace any unsuitable material which has been identified.
4.

INSTALLATION OF PIPES AND BOX CULVERTS

4.1

Damage During Installation

The Contractor shall:

(a) verify that the load capacity of the pipes / box culverts (and associated structures) will not be exceeded
during installation;
(b) ensure that pipes / box culverts are not damaged during transportation, handling, placement, backfilling
and subsequent construction activities; and
(c) if necessary, place sufficient protective material (in accordance with the Manufacturers Instructions and
design requirements) over the pipes / box culverts to prevent damage during construction activities.
Reinforced Concrete Pipes
Any damage to reinforced concrete pipes shall be classified in accordance with AS 4058 Clause 3.4 Workmanship
and Finish and subject to assessment in accordance with Table 5.1.
TABLE 5.1 ACCEPTABILITY OF DEFECTS
Defect Type

Pipe Wall

Joint Surface
Not Applicable

Acceptable

Acceptable after completion of approved

repair

Not Applicable

Not Applicable

Reject
Acceptable after completion of approved
repair
Acceptable after completion of approved
repair
Reject

Reject

Reject

4
5

Acceptable after completion of approved

repair
Acceptable after completion of approved
repair
Reject

Fibre Reinforced Pipes

Fibre reinforced pipes shall be rejected if fractures and cracks wider than 0.1 mm and deeper than 0.3 mm are
present.
4.2

Mortar

Sand for mortar shall comply with the requirements for fine aggregate in AS 2758.1. Cement for mortar shall be
as specified in Division 3 "Concrete" and mortar shall consist of one part cement to three parts sand.
4.3

Dimensions

The length shown on the drawings is:

(a) where pipes / box culverts terminate at headwalls, the length measured along the centreline of the pipes /
box culverts units;
(b) at other locations, the plan length measured from centre to centre of the drainage structure (unless
otherwise shown).
Nominal design gradients are calculated using the above lengths. Gradients are quoted in drainage schedules on
the drawings are for guidance only and gradients necessary to achieve quoted invert levels may vary from the
quoted gradients, depending on the overall dimensions of drainage structures.
4.4

Bedding

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Specification: Part 204 Installation of Stormwater Drainage

Bedding shall be Sa-C Type C Sand, spread to a minimum compacted depth in accordance with the following:
(a) 150 mm for pipes diameter 1500 mm or greater.
(b) 125 mm where verification testing is to be undertaken.
(c) 100 mm otherwise.
The Contractor shall arrange for trials to be conducted to verify a method of achieving the specified compaction.
Prior to use of the method, a HOLD POINT shall apply.
For pipes the bedding sand shall be rammed under both sides of the haunches of the pipe to a height of one third
the diameter of the pipe. For large box culverts, the foundation area shall be prepared in accordance with the
requirements shown on the drawings.
4.5

Placing

4.5.1

Concrete Pipes

Concrete pipes shall be placed and jointed in accordance with the Manufacturer's Instructions. Pipes shall be
placed with the female end upstream and with lifting holes (if any) uppermost. Lifting holes in pipes shall be
filled with plugs supplied by the pipe manufacturer for that purpose.
4.5.2

Small Box Culverts

Small box culverts shall be placed so that the joints between base slabs are located half way between the joints on
the crowns. Mortar or pipe sealant shall be used to seal the joint between the crown units and bases.
A bituminised tape (Densopol 60HT or equivalent) shall be used in accordance with the Manufacturer's
Instructions to seal the joints of abutting crown units. Taping shall be done immediately prior to backfilling to
minimise the risk of separation of the tape from the concrete surfaces.
Lifting hooks shall be cut off with a cutting disc, with both steel and concrete being ground away at least 5 mm
below the surrounding concrete surface. The surface shall then be finished flush with an epoxy putty (Bauer
Gemcrete 205 or equivalent) to give a minimum cover of 5 mm over the remnant lifting hook.
4.5.3

Large Box Culverts

Unless specified otherwise, crown units shall not be placed on the cast-in-place slab for a period of 48 hours after
placement of the base slab concrete.
No superimposed loads other than the culvert crown units shall be permitted on the base slab. If the Contractor
intends loading the base slab with vehicular or other traffic, full calculations demonstrating that the concrete has
sufficient capacity to support such loads shall be provided to the Superintendent.
Immediately prior to positioning crown units onto the base slab, a 15 mm layer of cement mortar (1 part cement :
3 parts sand) shall be placed into the recesses in the top of the base slab onto which the crown units are to be
placed. Excess mortar shall be removed to a minimum of 20 mm below the level of the base slab.
Following completion of the installation of the crown units and prior to commencement of backfilling, a stiff
cement mortar (1 part cement: 3 parts sand) shall be placed into the remaining spaces of the recess as shown on
the drawings.
Lifting hooks shall be cut off with a cutting disc, with both steel and concrete being ground away at least 5 mm
below the surrounding concrete surface. The surface shall then be finished flush with epoxy putty (Bauer
Gemcrete 205 or approved equivalent) to give a minimum cover of 5 mm over the remnant lifting hook.
4.6

Junctions

Where a junction is shown on the drawings it shall be constructed as a bandaged joint in accordance with
Clause 4.8 "Extension of Existing Pipes / Box Culverts". Backfill shall not be placed against junctions until the
following day.
The construction of the joint shall provide an unobstructed waterway of the specified dimensions in each of the
Culverts after completion of the joint.

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4.7

Specification: Part 204 Installation of Stormwater Drainage

Cutting Pipes / Box Culverts

Cutting of pipes / box culverts to provide appropriate lengths at joints and drainage structures shall be done in such
a manner that it does not affect the structural capacity of the pipes / box culverts. Reinforcement exposed during
cutting of pipes / box culverts shall be painted with a thick highbuild epoxy (Megapoxy P1 or approved equivalent)
applied in accordance with the Manufacturer's Instructions.
4.8

Extension of Existing Pipes / Box Culverts

Where existing pipes are to be extended, any existing headwalls or drainage structures shall be demolished and
disposed of by the Contractor.
Cutting of existing pipes shall be carried out as specified in Clause 5.7 above. Bandaged joints shall be constructed
and the joint strengthened with a concrete fillet (bandage) around the pipes forming the joint and extending at least
300 mm from the junction along the surface of each pipe. The fillet shall be a minimum of 100 mm thick and
shall be reinforced with SL62 mesh to AS 4671 completely encircling both pipes forming the joint, lapped 300 mm
and extending the full length of the fillet.
Backfill shall not be placed against fillet joints until the following day.
The construction of the joint shall provide an unobstructed waterway of the specified diameter in each of the pipes
after completion of the joint.
5.

BACKFILL OF TRENCHES AND REINSTATEMENT OF EXISTING PAVEMENTS

Backfill of trenches shall comply with Part 207 Trench Excavation and Backfill. Pipes / box culverts placed in
fill shall be protected from damage by construction machinery.
Reinstatement of any existing pavements which are to be retained shall comply with Part 208 Reinstatement of
Existing Pavements.
6.

EXCAVATION AT INLETS AND OUTLETS

The Contractor shall excavate as necessary to match the pipe / box culvert invert to the adjoining drainage
channels or natural surface.
Unless shown otherwise on the drawings, the excavation shall be uniformly graded at a maximum grade of 2% or
to the boundary of the road reserve, whichever extends the least. The excavation shall be the full width of the
pipe / box culvert apron, with batters not steeper than 6 horizontal to 1 vertical.
7.

CAST-IN-PLACE AND PRECAST CONCRETE DRAINAGE STRUCTURES

7.1

Scope

If the Principal has provided a design for the drainage structures, it will be based on cast-in-place structures and
the use of precast drainage structures shall be at the Contractor's risk. The information regarding location of
existing culverts and services may not be sufficiently accurate for the use of precast structures. Where normal class
concrete is specified on the drawings, the concrete shall comply with Part 326 Normal Class Concrete.
Junction boxes shall have inspection pit covers as detailed on the drawings. Notwithstanding any note on the
drawings to the contrary, junction boxes shall be provided with inspection pit covers complying with AS 3996,
Class D or AS 4198, Class H as appropriate.
Inspection pit covers shall be installed flush with the final surface.
Grated junction boxes and field gullies shall include covers and frames. Grates and frames shall be fabricated to
the dimensions shown on Drawing No. 4065, sheet 1. Welds shall be GP in accordance with AS 1554.1.
Side entry pit covers for single or multiple 900 mm x 450 mm openings shall be either:
(a)

Gatic heavy duty cast iron cover, GSEC945C;

(b)

Everlevel ductile iron (spherical graphite) cover, SEC945SG; or

(c)

PCP ductile iron cover, SEC945CIHD.

Exposed steel work other than cast iron shall be shall be hot-dip galvanised in accordance with AS 4680.
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7.2

Specification: Part 204 Installation of Stormwater Drainage

Foundation Preparation for Drainage Structures

Where detailed on the drawings, foundation preparation concrete shall be placed below cast-in-place structures.
Bedding shall be in accordance with Clause 4.4 "Bedding".
Excavation below the specified levels shall be filled with either Sa-C Type C Sand and compacted to the same
standard as the bedding or with Grade 10 concrete where foundation preparation concrete is to be placed under the
structure.
7.3

Formwork

Both internal and external surfaces of walls shall be formed. If the Contractor can demonstrate that the ground is
stable and will stand vertically without any distress or contamination of the concrete, the concrete may be cast
against the ground, provided that:
(a)

the wall thickness is increased by at least 50 mm over that detailed; and

(b)

the cover to reinforcement adjacent to the ground is increased by at least 50 mm.

External formwork shall be used for the top portion of junction boxes and gullies contained within the road
pavement in all cases. Formwork shall be used for all exposed faces of headwalls and drainage structures.
7.4

Precast Drainage Structures

Where a precast drainage structure is used, the external joint with the pipes / box culverts shall be strengthened
with a concrete fillet encircling the culvert at the joint. The fillet shall be a minimum of 100 mm thick 10 MPa
concrete (or rapid mix equivalent). The inside joint shall be rendered flush with the inside wall of the structure
with mortar (1 part cement and 3 parts sand) or equivalent.
8.

MINOR ACCESSES AND JUNCTIONS

Pipes / box culverts used under any minor accesses and junctions for side drains shall be placed in the centre of the
side drain with the same grade as the side drain. The pipes / box culverts shall allow unimpeded flow of water in
the side drain.
9.

SUBSOIL DRAINAGE

This Clause only applies where the construction of subsoil drainage is specified on the drawings or in the Contract
Specific Requirements.
Subsoil drainage shall be installed and the trench backfilled in accordance with the Manufacturers Instructions.
Following placement of the subsoil drain and prior to backfilling, a HOLD POINT shall apply.
Flushout points shall be provided where shown on the drawings. Flushout points shall consist of 100 mm diameter
UPVC pipe connected to the subsoil drain and rising vertically to approximately 100 mm below the finished
surface level and fitted with a threaded cap. A removable concrete cover (Everlevel IP100CF or equivalent) shall
be provided.
10.

PROPERTY DRAINAGE CONNECTIONS

Existing stormwater connections from private properties shall be maintained at all times.
11.

SEDIMENTATION

Soil and any other material entering the pipes / box culverts or drainage structures shall be removed so that the
pipe / box culvert provides an unobstructed waterway of the specified dimensions at all times up to the Date of
Practical Completion. Any sedimentation prevention measures (such as sediment traps, silt fences and straw bales)
shall be fully functional at the Date of Practical Completion.
12.

TEST PROCEDURES

The Contractor shall use the following test procedures (refer http://www.dpti.sa.gov.au/contractor_documents) to
verify conformance with the Specification:

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Specification: Part 204 Installation of Stormwater Drainage

TEST

PROCEDURE NO.

Sampling of Soil, Aggregates and Rocks

TP 226

Preparation of Samples

AS 1289.1

Site Selection by Stratified Random Technique

AS 1289.1.4.2

Field Density:

Nuclear Method

AS 1289.5.8.1

Moisture Content:

Oven Drying Method

AS 1289.2.1.1

Microwave Method

AS 1289.2.1.4

Modified Compaction

AS 1289.5.2.1

Rapid Method

TP 165(1)

Maximum Dry Density:

Dry Density Ratio

This test may only be used for control testing, not for verification testing.

TP 320

(1)

13.

HOLD POINTS

The following is a summary of Hold Points, vide Part 140 "Quality System Requirements", referenced in this Part:
CLAUSE
REF.

14.

HOLD POINT

RESPONSE TIME

3.5

Inspection after excavation

1 working day

4.4

Prior to use of compaction method for bedding

1 working day

9.

After placing subsoil drain and prior to backfilling

1 working day

MEASUREMENT

If measurement is required for the purpose of payment, the measurement of pipes / box culverts shall be based on
the length of installed Culvert and the measurement of kerb and gutter shall include the gutter across the openings
of gullies (which may include deflector vanes).

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15.

Specification: Part 204 Installation of Stormwater Drainage

VERIFICATION REQUIREMENTS AND RECORDS

The Contractor shall supply written verification that the following requirements have been complied with and supply the verification with the lot package.
CLAUSE
REF.
4.5.3

SUBJECT

PROPERTY

Placement of Large
Culverts: dimensions,
level and position
Culvert Bedding

Placement tolerances
Compaction

5.
7.

Backfill
Drainage Structures:
Concrete Requirements

7.

Placement of Drainage
Structures: dimensions,
level and position

4.4

Subsoil Drainage: level

and position

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TEST
PROCEDURE
As specified in
Part 130

TEST FREQUENCY

ACCEPTANCE LIMITS

As specified in Part 130

As specified in Clause 310.5 "Tolerances".

TP 320

The Contractor shall develop a method

specification in accordance with Clause 5.3

Not less than 90%

Compaction
Concrete
Requirements, vide
Division 3 "Concrete"

TP 320
As specified in
Division 3
"Concrete"

Refer Part 206

As specified in Division 3 "Concrete"

Refer Part 206

As specified in Division 3 "Concrete"

Variation in
cross-sectional
dimensions:
Misplacement from
specified position:
Permissible surface
irregularities:
Variation of reduced
levels of invert from
specified level:

As specified in
Part 130

As specified in Part 210

Within 6 mm of specified dimension

As specified in
Part 130
As specified in
Part 130
As specified in
Part 130

As specified in Part 130

Within 20 mm of specified position

As specified in Part 130

Less than 10 mm

As specified in Part 130

Misplacement from
horizontal position
Variation from
specified level

Tape Measure

Every 10 m

Within 10 mm of specified position, with the

proviso that, notwithstanding tolerances, the
invert of the structure shall not impede the
gravity flow of water into or from the structure.
Within 100 mm of specified position

Surveyors Level

Every 10 m

Within 30 mm of specified level; with the

proviso that, notwithstanding tolerances,
gravity flow of water to the drainage outlet shall
be provided

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Specification: Part 204 Installation of Stormwater Drainage

APPENDIX A
CULVERT INSTALLATION IN FILL
Cement Mortar
300

300

300

300

SINGLE AND MULTIPLE BOX CULVERTS

300 mm spacing where D is up to and
including 600 mm, 450 mm spacing
where D is over 600 mm.
300

300

D2
D

1/3 D

300

300

MULTIPLE PIPES

NOTE:
D

1/3 D

1. Not to scale.
2. All dimensions in millimetres.
3. D = Internal pipe diameter.
4. Refer to specification for
bedding and backfill
requirements

SINGLE PIPES

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